IMPORTANT SAFETY NOTICE - JLG Industries Telehandlers/534B-6_534B-8...IMPORTANT SAFETY NOTICE Safe operation depends on reliable equipment and proper operating procedures. Performing

IMPORTANT SAFETY NOTICE

Safe operation depends on reliable equipment and proper operatingprocedures. Performing the checks and services described in this manual willhelp to keep your Gradall Material Handler in reliable condition and use ofthe recommended operating procedures can help you avoid accidents.Because some procedures may be new to even the experienced operator werecommend that this manual be read, understood and followed by all whooperate the unit.

Danger, Warning and Caution notes in this manual and the FIEI Rough TerrainForklift Safety Manual will help you avoid injury and damage to the equipment.These notes are not intended to cover all eventualities; it would be impossible toanticipate and evaluate all possible applications and methods of operation forthis equipment.

Any procedure not specifically recommended by The Gradall Company mustbe thoroughly evaluated from the standpoint of safety before it is placed inpractice. If you aren’t sure, contact your Gradall Material HandlerDistributor before operating.

Do not modify this machine without written permission from The GradallCompany.

NOTICE

The Gradall Company406 Mill Avenue, S.W., New Philadelphia, Ohio 44663

The Gradall Company retains allproprietary rights to the infor-mation contained in this manual.

The Company also reserves theright to change specifications with-out notice.

Gradall is a registered trademark forhydraulic excavators, hydraulic ma-terial handlers and attachments man-ufactured by The Gradall Company.

Form No. 48729

INTRODUCTIONGeneral

The manual provides important informationfamiliarize you with safe operating procedures andoperator maintenance requirements for the Gradall/534-B Material Handler.

If you have any questions regarding the materialhandler, contact your Gradall Material HandlerDistributor.

Operator Qualifications

Operators of the material handler must be in goodphysical and mental condition, have normal reflexesand reaction time good vision and depth perceptionand normal hearing. He/she* must not be usingmedication which could impair his abilities nor beunder the influence of alcohol or any other drugduring the work shift.

The operator should also possess a valid, applicabledriver’s license and must have completed a course oftraining in the safe operation of this type of materialhandling equipment.

In addition, the operator must read, understand andcomply with instructions contained in the followingmaterial furnished with the material handler:

This Operator’s ManualFIEI Rough Terrain Forklift Safety ManualGradall Material Handler Safety ManualAll instruction decals and platesAny optional equipment instructions furnished

The operator must also read, understand andcomply with all applicable Employer, Industry andGovernmental rules, standards and regulations.

Regardless of previous experience operating similarequipment, the operator must be given sufficientopportunity to practice with the 534-B MaterialHandler in a safe, open area (not hazardous to peopleor property) to develop the skills and “feel” requiredfor safe, efficient operation.

¬Though no offense or discrimination is intended,only the masculine pronouns will be usedthroughout the remainder of this manual.

Orientation

When used to describe location of componente inthe material handler, the directions front, rear,right and left relate to the orientation of a personsitting in the operator’s seat.

Related Manuals & Decals

Separate publication are furnished with thematerial handler to provide informationconcerning safety, replacement parte, maintenanceprocedures, theory of operation and vendorcomponents. Replacement manuals, decals andinstructions plates can be ordered from your GradallMaterial Handler Distributor.

Serial Number Location

Specify Model and Serial Numbers when orderingparts and when discussing specific applications andprocedures with your distributor. The model/serialnumber plate located on the cate wall to the rightof the Operator’s seat pedestal.

Nomenclature

The illustrations on page 3 include nomenclatureapplied to major components of the material handler.The term “handler” will be used throughout thebalance of this manual in place of the words “materialhandler”.

2

NOMENCLATURE

3

SAFETY HIGHLIGHTS

Read and understand this manual, the Gradall Ma-terial Handler Safety Manual and all instructionaldecals and plates before starting, operating or per-forming maintenance procedures on this equipment.

Most safety notes included in this manual involvecharacteristics of the Model 534-B Material Handler.Refer to the FIEI Rough Terrain Forklift SafetyManual and the Gradall Material Handler SafetyManual for safety precautions relating to generalmaterial handling procedures and practices.

Operators of this equipment must have successfullycompleted a training program in the safe operationof this type of material handling equipment.

Regardless of previous experience operating similarequipment, the proper operator must be given sufficientopportunity to practice with the 534-B MaterialHandler in a safe open area (not hazardous to peopleor property) to develop the skills and “feel” requiredfor safe, efficient operation.

This symbol indicates a hazard which couldwould result in high probability of death orserious injury if proper precautions are nottaken.

This symbol indicates a hazard which couldresult in death or serious if properprecautions are not taken.

This symbol indicates a hazard which couldresult in injury or damage to equipment orproperty if proper precautions are not taken.

Watch for these symbols; they are usedto call your attention to safety notices.

4

D A N G E R

Decals Inside Cab

Located on Dashboard9103-3310

Located on DashboardPart No.9103-3089

Located on DashboardPart No. 9100-3040


Located on FirewallPart No. 9103-3010

Located on DashboardPart No.9103-3014


WARNING! LEVEL GRADALL HANDLER BEFORE LIFTINGANY LOAD ABOVE 4 FEET

5

DO NOT OPERATE MACHINEWITHOUT PROPER CAPACITYCHART IN PLACE

TO PREVENT ENGINE RING GEAR DAMAGE,WAIT 10 SECONDS AFTER ENGINEROTATION STOPS BEFORE AT ATTEMPTINGTO RESTART.

Decals Inside Cab (cont.)




WARNING: SHUT OFF ENGINE AND SET BRAKES BEFORE LEAVING GRADALL HANDLER UNATTENDED

WARNING:ON GRADES AND UNEVEN GROUND PLACE FORKSIN CARRY POSITION (APPROX. 12" ABOVE GROUND)BEFORE MOVING GRADALL HANDLER

WARNING:OPERATOR PROTECTION (SUCH AS HARD HATS,

SAFETY GLASSES AND/OR EAR MUFFS) SHOULD BEWORN WHEN JOB CONDITIONS WARRANT




6

BRAKING CAPACITY ISREDUCED WHEN ENGINE

IS NOT RUNNING. 9103-3135

9103-3244

9100-3050

9100-3036

9100-3041


STARTBUTTON

Located on Front Face of DashboardPart NO. 9104-3207

WARNING

Located on Manual HolderPart No. 9103-3103

Located on Manual HolderPart No. 9106-3031

Located on Boom Lever KnobPart No. 9100-3044


9104

-32

07

DO NOT OPERATE THIS MACHINEWITHOUT FIRST READING THEOPERATOR’S MANUAL. IF AMANUAL IS NOT AVAILABLE,REFER TO AN AUTHORIZEDGRADALL DEALER.

9103-3103

7

PARK BRAKE

PULL TO SET

PUSH TO RELEASE

PARKING BRAKELIGHT IDENTIFICATION

PARK BRAKEINSTRUCTIONS

FOR MINIMUM CLEARANCES OF HIGH VOLTAGE LINES IN EXCESS OF 50,000 VOLTS, SEEYOUR LOCAL STATE ANDFEDERAL REGULATIONS DO NOT DEFACE OR REMOVED THISSIGN FROM THIS MACHINE

Located on MudguardPart No. 8360-1011


DEATH

UNLAWFUL

OR INJURY MAY RESULT FROMCONTACTING ELECTRICAL LINES.

TO PLACE ANY PART OF THISMACHINE OR LOAD WITHIN 10FEET OF HIGH VOLTAGE LINESOF UP TO 50,000 VOLTS.


Optional Lift Capacity Charts arelocated on Firewall.

9

GFHGHGFH

9103-3311

8

88

CAPACITY CHART: MODEL 5348-8RATED CAPACITY 2 FT. LOAD CENTER

FUEL - DIESEL

Located on Fuel TankPart No.9100-3052

Located on RadiatorPart No 9103-3011

Located on Boom HeadPart No. 9103-3023

Located Left of Cab DoorPart No. 7702-3003

Decals Outside Cab

EXTINGUISH ALL OPEN FLAMEAND SMOKING MATERIALSWHEN REFUELING.

9100-3052

DO NOT INSERT HAND INOPENING WHILE ENGINEIS RUNNING

9103-3011

CHECK TO ASSURE QUICK SWITCHPIN IS FULLY ENGAGED AND LOCKEDAFTER ATTACHMENT CHANGE

2-9103-3023

Located on Hydraulic Reservoir & Left of Cab DoorPart No. 9104-3211

Located on RadiatorPart No. 9100-3032

Located on Fuel TankPart No. 7702-3308

TIRE PRESSURE55 PSI

Located on Wheel Rims REAR: 55 psi Part No. 9105-9104 FRONT: 65 psi

HYDRAULIC OILLocated on Hydraulic Reservoir

Part No. 7702-3006

Located on BoomPart No. 9100-3031

USE TWOHANDS WHENCLIMBING ONMACHINE. 7702-3003

9

NO RIDERS9104-3211

COOLANT9100-3032

DIESEL FUEL7702-3308

7702-3006

DO NOT USE THIS MACHINEFOR LIFTING PERSONNEL.

Located on MudguardPart No. 9104-3215

DO NOT STAND UNDERLOAD OR BOOM


HOT EXHAUSTLocated on Exhaust Guard

Part No. 7734-3018

Decals Outside Cab (cont.)

PINCH POINT AREATO PREVENT INJURY, KEEPCLEAR ANYTIME MACHINEIS RUNNING

Located Below Boom PivotPart No. 9104-3209

DO NOT USE BOOMAS WALKAWAY


Located on RadiatorPart No. 9104-3210

9104-3215

9104-3217

10

9104-3209

9104-3216

PRESSURIZED-COOLING SYSTEM

REMOVE CAPSLOWLY

9104-3210

HAND SIGNALSStandard Signals - When handler work conditionsrequire hand signals, they shall be provided orposted conspicuously for the use of both signalmanand operator. No handler motions shall be madeunless signals are clearly understood by bothsignalman and operator.

Special Signals - When signals for auxiliaryequipment functions or conditions not covered arerequired, they shall be agreed upon in advance bythe operator and signalman.

Instructions - When it desired to give instructionsto the operator other than provided by theestablished signal system all handler motions shallfirst be stopped.

EMERGENCY STOP - With botharms extended laterally hands opendownward, move arms back andforth.

EXTEND TELESCOPIC BOOM -With both hands clenched, pointthumbs outward.

MOVE LOAD OUT HORIZONTALLYWith either arm extended, handraised and open toward direction ofmovement, move hand in direction ofrequired movement.

CLOSE BUCKET - Hold one handclosed and stationary. Rotate otherhand in small vertical circle withforefinger pointing horizontally atclosed hand.

STOP - With either arm extendedlaterally, hand open downward,move arm back and forth.

RETRACT TELESCOPIC BOOM -With both hands clenched, pointthumbs inward.

MOVE LOAD HORIZONTALLY -With either arm extended, handraised and open toward direction ofmovement, move hand in direction ofrequired movement.

OPEN BUCKET - Hold one handopen and stationary. Rotate otherhand in small vertical circle withforefinger pointing horizontally atopen hand.

RAISED BOOM - With either armextended horizontally, fingerclosed, point thumb upward.

RAISED LOAD VERTICALLY - Witheither forearm vertical, forefingerpointing up, mover hand in smallhorizontal circle.

TILT FORKS UP - With one arm heldat side, extend other arm upward atabout 45°.

MOVE SLOWLY - Place one handmotionless in front of hand givingmotion signal. (Raise load slowly isshown.)

LOWER BOOM - With either armextended horizontally, fingersclosed, point thumb downward.

LOWER LOAD VERTICALLY - Witheither arm extended downwardforefinger pointing down, move handin small horizontal circle.

TILT FORKS DOWN - With one armheld at side, extend other armdownward at about 45°

THIS FAR TO GO - With hands raisedand open inward, move handslaterally, indicating distance to go.

11

STOP ENGINE - Draw thumb orforefinger across throat.

The standard cab is open on three sides and includesan overhead guard to provide protection fromfalling objects.

A fully enclosed cab with Plexiglass windows and alokable door is available as an option. The cabdoor can be secured in the fully opened or closedposition. Be sure the door is fully secured whenoperating the handler.

The operator’s seat is equipped with a seat belt andincludes fore and aft adjustment to compensate for

variations in operator size. The adjustmentrelease/lock lever is located beneath front edge ofseat belt at all times.

An optional windshield wiper is available for usewith enclosed cabs. An ON/OFF control switch islocated on the wiper motor.

A variable speed defroster fan is available for usewith enclosed cabs. An On/Off control switch andspeed control are located on the base of the fan.

A variable speed heater fan is available for use withunits equipped with a heater. An ON/OFF/SPEEDCONTROL knob is located on the dashboard. Hotwater to the heater can be controlled by a valve atthe engine.

OPERATOR’S CAB

Never operate the handler unless theoverhead guard is in place and in goodcondition.

CONTROL AND INSTRUMENT IDENTIFICATION

*Items preceded by an asterisk and may not be furnished on your handler.

12

NOTE: These descriptions are provided in alpha-betical sequence in accordance with the nomen-clature shown on the facing page.

Accelerator Pedal: The accelerator pedal is con-nected to the engine speed control by a cable toprovide accurate engine speed control. Depress pedalto increase speed and release pedal to decrease speed.

Ammeter: The ammeter indicates the charge/dis-charge rate of the battery charging system. With theengine running, a discharge reading or a continuinghigh charge rate indicates a problem in the system.

Auxiliary Control Lever (optional): This lever is usedto control optional hydraulic attachments. Followdecal instructions for lever handler movements.

Boom Extend/Retract Lever: This lever controlsboom extension and retraction. Speed is proportionalto lever actuation. Move lever to right to extendboom or to left to retract boom.

Boom Raise/Lower Lever: This lever controls raisingand lowering the boom. Speed is proportional to leveractuation. Pull lever to rear to raise boom or pushlever forward to lower boom.

Brake/Inching Pedal: The brake/inching pedal pro-vides service brake control and inching control. Toactivate the brakes, push the pedal down. To releasethe brakes, remove foot from pedal. When full brakesare applied, the rear hydraulic drive is disconnected.When partial brake/inching pedal movement is used,the front wheel drive is disconnected from thetransmission. The inching feature of the rear wheeldrive system provides for smooth machine operationat low speeds and high engine rpm.

Park Brake Control Knob: The park brake controlknob is located to the left of the operator and is usedto apply and release the parking brake. To apply theparking brake, pull the knob up. To release theparking brake, push the knob down.

Carriage Tilt Lever: This lever controls tilt of thefork carriage. Speed is proportional to lever act-uation. Push lever forward to tilt down or pull lever torear to tilt up.

Engine Coolant Temperature Gage: This gage dis-plays engine coolant temperature. Normal operatingtemperature is 180-200°F. (82-93°C.)

Engine Oil Pressure Gage: This gage displays engineoil pressure. Normal operating pressure is 35-50 psi(241-345 kPa).

Forward/Reverse Lever: This lever engages forwardor reverse travel. Push lever fully forward for forwardtravel; pull lever fully to rear for reverse travel orRead and understand this manual and themove lever to centered position for neutral.

Fuel Gage: This gage displays level of fuel in fueltank.

Heater Fan Switch (optional): This rotary switchcontrols heater fan. Rotate clockwise to start fan.Continued clockwise rotation controls fan speed.

Horn Button: Depress button to sound horn.

Hourmeter: This meter indicates total time of engineoperation in hours and tenths of hours.

Ignition Switch: This switch is actuated by a key. InON position (turned clockwise) voltage is availablefor all electrical functions. Turn key counterclock-wise to stop engine and remove voltage from allelectrical functions.

Level indicator: This indicator (a bubble level)enables the operator to determine the left to rightlevel condition of the handler.

Light Switch (optional): This switch controls optionallighting which may be provided with the handler.

Machine Level lever: This lever controls the verticalrelationship of the handler frame to the front axle.Move the lever to the right to tilt frame to right ormove lever to left to tilt frame to left.

Rotating Beacon Switch (optional): This switchcontrols operation of rotating beacon.

Seat Lock Release Lewer: This lever unlocks andlocks seat position adjustment. Lift lever to unlockand release lever to lock adjustment.

Start Button: The start button controls operation ofthe engine starter motor. With ignition switch in ONposition, depress start button to actuate starter motor.Release button to disengage starter motor.

Steering Wheel: The steering wheel controls theangle of rear axle wheels. Turning the steering wheelto the right causes a right turn by angling rear wheelsto left. A left turn is caused by angling rear wheels toright.

Transmission Speed Selector Lever: This lever per-mits selection of three speed ranges for forward andreverse travel.

Transmission Temperature Gage: This gage displaystemperature of transmission fluid. Normal operatingtemperature is 180-200°F. (82-93°C.).

A brief description of controls and Instru-ments is provided here as a convenience forthe operator. These descriptions DO NOTprovide complete operating instructions.Read and understand this manual and theFIEI Rough Terrain Forklift Safety Manualbefore operating the handler.

13

Use extreme caution when checking items beyond your normal reach. Use an approved safety ladder.

Before removing filler caps or fill plugs, wipe all dirtand grease away from the ports. If dirt is allowed to

Service the unit in accordance with the lubricationand maintenance schedule.

CHECKS AND SERVICESBEFORE STARTING ENGINE(To be performed at beginning of each work shift)

Inspect all structural members, including attach-ment, for signs of damage.

enter these ports, it can shorten the life of o-rings,seals, packings and bearings.

When adding fluids or changing filter elements,refer to the lubrication section of this manual todetermine the proper type to be used.

If spark arrestors are required, be sure they are inplace and in good working order.

Complete all required maintenance before operating unit.

Inspect unit for obvious damage, vandalismand needed maintenance . Check for signs of fuel,lubricant, coolant and hydraulic leaks. Open allaccess doors and look for loose fittings, clamps,components and attaching hardware. Replacehydraulic lines that are cracked, brittle, cut or showsigns of abrasion.

14

Starting Engine

1. Check to be sure that all controls are in neutraland that all electrical components (lights, heater,defroster, etc.) are turned off. Set parking brake.

2. Insert ignition key and turn clockwise to ONposition.

3. Depress accelerator pedal approximately 1/4 to1/3 of travel from top.

NOTE: If temperature requires the use of a startingaid, and if your handler is equipped with a factory-installed ether starting aid, depress cold weather

Cold Weather Starting Aids

Diesel engine ignition is accomplished by heatgenerated when fuel/air mixture is compressedwithin the cylinders. Because this heat may beinsufficient to start a cold engine in cold weather,the use of starting aids has become common practice.

Because of the wide variety of starting aids availableit would be impractical to attempt to provide,

Normal Engine Operation

Observe gages frequently to be sure all enginesystems are tunctioning properly.

The ammeter shows the charge/ discharge rate of thebattery charging system. With the engine running, adischarge reading (-) or a continuing high chargereading (+) indicates a problem in the batterycharging system.

Be alert for unusual noises or vibration. Whenan unusual condition is noticed, stop machine in asafe position and shut off engine. Determine causeand correct problem before continuing.

ENGINE OPERATIONNOTE: If engine is being started at beginning of work shift be sure to perform all “CHECKS ANDSERVICES BEFORE STARTING ENGINE” (page 6).

button one time only before starting engine. If youuse a different starting aid, be sure to followmanufacturer’s instructions carefully. Excessive ethermay damage engine.

specific instructions for their use in this manual.Carefully follow instructions furnished with yourstarting aid.

If you use a starting aid employing ether or asimilar substance pay particular attention tomanutacturer’s warnings.

Avoid prolonged idling . Idling causes enginetemperature to drop and this permits formation ofheavy carbon deposits and dilution of lubricating oilby imcompletely burned fuel. If the engine is notbeing used, turn it off.

Always keep engine covers closed while engine is running (it furnished).

15

Depressing start button while engine fly- wheel is rotating can cause serious damage to engine and/or starting motor.

Depress start button to engage starting motor.Release button immediately when engine starts. Ifengine fails to start within 20 seconds, releasebutton and allow starting motor to cool for a fewminutes before trying again.

After engine starts, observe oil pressure gage. Ifgage remains on zero for more than ten seconds,stop engine and determine cause. Correct causeof malfunctioning before restarting engine.Normal engine oil pressure should be in range of35 - 50 psi (241 - 345 kPa).

Warm up engine at approximately 1/2 throttleuntil engine coolant temperature reachesoperating range of 180 - 200°F. (82 - 93°C.).

4.

5.

6.

Stopping the Engine

Operate engine at idle speed for a few minutesbefore turning it off. This allows engine coolantand lubricating oil to carry excessive heat awayfrom critical engine areas.

Do not “gun” engine before shut down; thispractice causes raw fuel to remove oil film from

The safety efficiency and service life of your unitwill be increased by performing the operationalchecks listed below. Items preceded by an asterisk(*) are optional and may not be furnished on yourmachine. Check items during warm-up period.

cylinder walls and dilute lubricant in crankcase.

To stop the engine, allow engine to run at idle for afew minutes, this is to allow the turbo componentsto cool. Turn key counter clockwise to stop position.Be sure to remove key from ignition switch beforeleaving cab.

Forward and reverse travel in all gears

“Inching” travel - should be smooth throughfull pedal travel

Horn and back-up alarm

All boom and attachment functions - full strokein both directions

Hydraulic Filter Condition Indicator - observetorque converter temperature gage after startingnormal operation. When needle has been inoperating range for an hour or so, stop handler ina safe area and set parking brake. With enginerunning at full RPM check hydraulic filtercondition indicator. When yellow flag fillsindicator window filter is clogged and hydraulicoil is bypassing filter. Filter must be changedbefore reaching bypass condition (change beforeyellow flag reaches midpoint of window).

WARM UP & OPERATIONAL CHECKS(To be performed at beginning of each work shift)

Complete all required maintenance before operating unit

When engine warms to operating range, checkthe following items:

Heater defroster and windshield wiper

Operating lights and rotating beacon

Low brake pressure light - should go out withengine running above idle

Ammeter - should show low charging rate aftercharging system has replaced starting drain

Service brake, parking brake and parking brakelock.

1.

2.

3.

4.

5.

6.

7.

8.

9

10.

Continued operation with hydraulic fluidby-passing the filter (yellow flagshowing) can cause severe damage tohydraulic system components.

16

*

*

General

The brake system furnished on the handler includes aservice brake, inching brake and parking brake.

Because service braking and “inching” (slow travel)functions overlap, some features of inching will bediscussed here. Refer to Drive Train Section foradditional information on inching travel.

Inching Travel

Overlap between service braking and inching occursbecause the same foot pedal controls both functions,and also because both functions control travel speed.However, the methods of controlling travel speed arequite different: service braking involves a controlledstopping force applied to the front wheels while,inching involves a controlled driving force applied tothe rear wheels.

The service brake/inching pedal has three separatefunctions:

As illustrated, the three functions occur in sequenceas service brake/inching pedal is depressed from topto bottom of stroke.

Practice inching/braking in a safe, open area until you are thoroughly familiar with response of machine to pedal travel.

BRAKE SYSTEM

Service Brakes

The service brake is applied to the front wheels of thehandler.

Oil for the brakes comes from the pilot circuit pump,thru an accumulator charging valve and the accumu-lator. When the service/inching brake pedal is de-pressed far enough to actuate the brake valve, thehydraulic oil flows to the wet disc brakes in both frontwheel hubs. The pressure compresses the brake discs.

Parking Brakes

The parking brakes are also applied at the wet discbrakes in the front axles.

TO APPLY THE PARKING BRAKE, pull up on theparking brake knob located to the left of the oper-ator’s seat. This opens the parking brake circuit todump, allowing a spring in the wet disc brakeassembly to compress the discs, applying the brakes.

TO RELEASE THE PARKING BRAKE, push downon the parking brake knob.

When the handler is not being used, with the engineshut off, the parking brakes must be applied.

It disconnects front drive axle from transmission.

It controls hydraulic flow to rear axle drive motors(hydraulic flow regulates speed).

It applies service brake.

1.

2.

3.

17

STEERING SYSTEM

Ninety degree rear wheel power steering is providedto reduce operator fatigue and to permit highmaneuverability in close quarters.

It is important that the operator practicemaneuvering the handler in a safe, open area untilhe becomes thoroughly familiar with steeringresponse and clearance required for tailswing andload when turning.

FRONT OUTRIGGERS (2) (OPTIONAL)

Front outriggers are provided in order to raise thefront tires off of the ground level while working, thusimproving the overall stability of the handler.

Two outrigger control levers are located to the righthand side of the operator ’s seat. Pushing forward onthe lever lowers the outriggers, and pulling back onthe lever raises them.

Be alert for any increase in eftort needed tosteer. It any difference is noted, notifymaintenance personnel immediately forcorrection. It power assist feature shouldfail for any reason IT WOULD BECOMEVERY DIFFICULT TO STEER. For thisreason it is extremely important that youNEVER TURN ENGINE OFF WHILETRAVELING.

In the event power steering tails, stop assoon as possible. Do not drive unit untilproblem has been corrected.

18

General

The drive train provides two and four wheel driveand includes the engine, torque convertertransmission, drive shaft and front and rear drivingaxles.

Inching travel is directly related to drive trainfunctions and will be discussed in this section.

Two & Four Wheel Drive

The drive train is designed to provide two wheeldrive (front axle driving) or four wheel drive (both)front and rear axles driving.

Under certain conditions, changing from four wheeldrive to two wheel drive may cause a difference inthe way the machine responds to steering, brakingand drive controls. Always be aware of which travelmode you are using.

There are two ways to disengage rear wheeldrive:

NOTE: Rear drive axle can also be disengaged inresponse to overload in associated electricalcircuitry causing automatic reset type circuitbreaker to trip (open). Breaker will close again inapproximately ten seconds.

Torque Converter

There are no operator controls for the torqueconverter. It functions automatically to permitstarting from a standstill in any transmission speedrange.

An oil temperature gage is provided to indicateoperating temperature of torque converter/trans-mission. Normal operating temperature is 180-200°F. (82- 93°C.). If overheating occurs, attemptto lower temperature by traveling in a lower gear. Ifnecessary, stop and allow torque converter to coolwith engine running and gear selector in neutral. Besure radiator fins are clean.

Transmission

The transmission provides three speed ranges forboth forward and reverse travel.

*With rear planetary hubs disengaged

There are three operator controls for thetransmission:

Front Driving AxleThe front driving axle includes a differential andplanetary drive hubs and is powered by a drive shaftfrom the transmission. The service brake/inchingpedal is the only operator control for the front axle(refer to Inching Travel heading).

DRIVE TRAIN

Shift to third gear (rear axle drive is engaged onlyin first and second gears)

Disengage rear planetary hubs (refer to RearDrive Axle heading in this section)

1.

2.

Gear Selector Lever (for 1st, 2nd and 3rd gears)

Direction Selector lever (for forward, neutraland reverse)

Service Brake Inching Pedal (refer to InchingTravel heading in this section)

Release parking brake and hold handler inposition using service brake.

Move gear selector to appropriate speed range(1st. 2nd or 3rd gear). The gear selector may beshifted while traveling. When traveling downhill,use the same gear needed to travel up the hill.

To Operate Transmission:

Move direction selector to forward or reverseposition.

Release service brake and depress accelerator toattain appropriate speed.

Stop handler by releasing accelerator andapplying service brake.

Move direction selector to neutral position.

Apply parking brake.

Never shift gear selector or directionselector to cause a sudden change oftravel speed or direction. Such a changecould cause load to shift or machine to tipover. Reversing direction while travelingcan also damage transmission.

Continued operation of overheated torqueconverter/transmission can cause seriousdamage to these components.

1.

2.

3.

1.

2.

3.

4.

5.

6.

7.

19 continued...

Rear Driving Axle

The rear driving axle includes planetary hubs whichare powered by hydraulic motors mounted on theinner face of the hubs. HYdraulic flow to drivemotors is provided only in first and second gearspeed ranges. Drive motors are free-floating in thirdgear.

To Disengage Rear Driving Hubs:

To Engage Rear Driving Hubs: Repeat procedure.

NOTE: If machine is moved with keeper pin plateremoved, input shaft pin will pop out.Hydraulic flow to rear axle drive motors iscontrolled electrically. An automatic reset typebreaker is included to prevent damage fromoverload. If circuit breaker trips (opens) rearaxle drive will be inoperative for approximatelyten seconds until breaker resets. Notifymaintenance personnel if circuit breaker tripsrepeatedly.

To determine whether circuit breaker has tripped,attempt to move machine using inching travel. Ifmachine does not respond to inching travel pedal,circuit breaker is open.

Inching Travel

Inching travel is provided to permit very slow travelwhile maintaining high engine speed for otherfunctions. Because inching travel depends onhydraulic flow to rear axle drive motors, inching

travel functions only in first and second gears. Thereis no hydraulic flow to drive motors in third gear.

Inching travel is controlled by the servicebrake/inching travel pedal. This pedal has threeseparate functions:

As illustrated, the three functions occur in sequenceas pedal is depressed from top to bottom of stroke.

To Engage Inching Travel:

To resume normal travel release service brake/inching travel pedal. Depress accelerator pedal toattain appropriate speed.

Continuous driving for two miles or morein third gear, with rear driving hubsengaged, can damage hydraulic drivemotors.

Apply parking brake and remove key fromignition switch.

Remove thumb screws or hex head cap screwsfrom keeper pin plate.

Remove and rotate plate (cup out-engaged-cupin-disengaged).

Secure plate using thumb screws or hex head capscrews.

Repeat procedure for other hub.

It disconnects front drive axle fromtransmission.

It controls hydraulic flow to rear axle drivemotors (hydraulic flow equals speed).

It applies service brake.

Depress service brake/inching travel pedalapproximately 1-1/2 inches to disengage frontdriving axle from transmission. At this point reardrive motors are receiving full flow and travelspeed will not have changed.

Continue to depress pedal to reduce speed-themore pedal travel, the less speed.

To stop, depress pedal fully.

OR

Practice inching/braking in safe, openarea until you are thoroughly familiar withresponse of machine to pedal travel.

1.

2.

3.

1.

2.

3.

20

1.

2.

3.

4.

5.

If handler must be moved, when the engine is notworkable, extreme care should be used because:

We recommend that the unit be pushed, not towedand that the unit be attached firmly to the pushingvehicle because the handler brakes are released.

MOVING HANDLER (Emergency Only)

With the engine not operating there will be NOsteering.With the wheel hubs adjusted to permit move-ment, ther will be NO brakes.

Place blocks on wheels to prevent movement.On both rear axles, reverse the hub disengagementcaps.**Loosen front hub cover bolts equally until covermoves 3/16" to 1/4". This released the wet discbrakes. ***

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If the handler is to be moved, do the following:

**In Disengaged **Out Engaged

** Back off 4 bolts

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Leveling

The handler is designed to permit tilting main frameeight degrees to left or right to compensate foruneven ground conditions.

A level indicators located on upper portion of frontwindow frame to permit operator to determine thatmachine is or is not level.

The rear axle pivots at the midpoint of the mainframe to help assure that wheels will remain incontact with ground. A hydraulic cylinder providesa rigid connection between front axle and mainframe to help assure a solid work platform andpermit tilting main frame to left or right.

NOTE:The frame leveling function is provided onlyto level the machine before lifting or placing a load.Do not attempt to use leveling feature to turn on ortravel across a slope.

Boom

The three section hydraulically operated boomprovides maximum reach of 36 feet abovehorizontal at 70ø elevation and 21 feet forward offorward edge of front tires at 0ø elevation (measuredto heel of standard forks mounted on standardcarriage). Boom travel extends from 4ø belowhorizontal to 70ø above horizontal.Raise boom by pulling boom lever to rear and lowerboom by pushing boom lever forward.Boom extension and retraction is accomplished by ahydraulic crowd cylinder anchored at rear of boomsection no. 1 and at front of boom section no. 2 andalso by a cable and push beam arrangement withinthe boom sections. Extension or retraction of attachmentboom section no. 2 is always equaled by acorresponding movement of boom section no.3

A hydraulic cylinder is located within the boomhead to tilt the fork carriage or other attachmentback and forth as required.

To Level Handler:

The tilt cylinder is controlled by carriage tilt/machine level lever. Push lever forward to tiltattachment down or pull lever to rear to tiltattachment up.

Extend boom by moving boom lever to right andretract boom by moving boom lever to left.A compensating cylinder is pinned to main frameand to base of boom section no. 1. As boom israised, oil is transferred from rod end ofcompensating cylinder to rod end of attachment tiltcylinder. Lowering boom causes transfer of oil frombarrel end of compensating cylinder to barrel end ofattachment tilt cylinder. This transfer of oil causesextension and retraction of tilt cylinder to maintainangle of attachment as boom is raised and lowered.

All cylinders related to boom (attachment tilt, raise/lower and extend/retract) are protected by pilotoperated check valves which prevent load fromfalling in event of a broken hydraulic hose or tube.

MATERIAL HANDLING

Raising the boom (loaded or unloaded)when handler is leaning to the side cancause machine to tip over with little or nowarning.

Position machine in best location to lift or placeload and apply brake.

Observe level indicator to determine whethermachine must be leveled. Note position ofindicator for later realignment.

If necessary, position boom in carry position andmove carriage tilt machine level lever to left orright to level machine. Move lever to left to lowerleft side of frame or move lever to right to lowerright side of frame.

Lift or place load as appropriate.

Retract and lower boom to carry position.

Realign frame to position noted in step 2.

If handler cannot be leveled using levelingsystem, do not attempt to raise or placeload. Have surface leveled.

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Attachments

Although the carriage/fork combination is mostfrequently used, a number of other attachmentsavailable for use with the handler. 180ø and 100øswing forks are available. A material bucket can beprovided for light duty work. A truss boom isavailable to extend maximum reach and height andcan be fitted with a winch when required. Consultyour Gradall Material Handler Dealer for infor-mation on attachments designed to solve specialmaterial handling problems.

Attachments Capacities

The Rated Capacity Chart located on left side ofdashboard indicates maximum capacities forhandlers equipped with standard carriage/forkcombination. These capacities apply only tostandard carriage, fork combination and cannot beused for other attachments.

Attachment Installation

A serial number plate Is attached to all attachmentsand indicates maximum capacity for thatattachment. However, the capacity shown onthis plate may be incorrect in relation to yourmachine.

Refer to Attachment Capacity Plate located belowSerial Number Plate on right cab wall for correctmaximum capacity for all attachments furnishedwith your machine. If attachment in question is notlisted on this plate contact factory for maximumcapacity.

Refer to Operating Procedures and Techniquessection for instructions on proper use ofinformation shown on capacity plates.

Depress button and remove lock pin from quickswitch latch pin.

Depress handle fully to engage latch pin inattachment and install lock pin in latch.Raise handle to retract latch pin fully.

Position boom head attachment pin fully in recessof attachment. Tilt upward slightly to assure fullengagement.

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This section highlights some common proceduresand discusses areas which may be new to even theexperienced operator.

Hydraulic Controls

All boom and attachment movements are governedby hydraulic controls. Rapid, jerky operation ofhydraulic controls will cause rapid, jerky movementof the load. Such movements can cause the load toshift or fall or may cause the machine to top over.

Feathering

Feathering is a control operation technique used forsmooth load handling. To feather controls, movecontrol lever very slowly until load begins to move,then gradually move lever further until load ismoving at desired speed. Gradually move levertoward neutral as load approaches destination.Continue to reduce load speed to bring load to asmooth stop. Feathering effect can be increased bylowering engine speed at beginning and near end ofload movement.

Boom Control Lever

The boom control lever can be positioned to causeindividual boom movements or combinations ofboom movements as illustrated.

With boom raised above horizontal, forks can beinserted under a load by moving boom control leverforward and to the right until forks move forwardhorizontally.

With boom raised above horizontal, forks can beremoved from a load by moving boom control leverback and to the left until forks move rearwardhorizontally.

With boom lowered below horizontal, forks can beinserted under a load by moving boom control leverback and to the right until forks move forwardhorizontally.

With boom lowered below horizontal, forks can beremoved from a load by moving boom control leverforward and to the left until forks move rearwardhorizontally.

The closer the boom to horizontal, the less boomraise/lower movement required for inserting andremoving forks.

Carriage Tilt/Machine Level Lever

Move lever to left to the tilt forks down and movelever to rear to tilt forks up.

Move lever to left to tilt main frame to left and movelever to right to tilt frame to right.

OPERATING PROCEDURES & TECHNIQUES

Always move boom to carry position(horizontal or below before levelingframe. Attempting to level machine withboom raised may caused it to tip over.

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General

The rated capacity chart, located on left side ofdashboard, indicases maximum load capacities forhandlers equipped with standard carriage/forkcombination. These capacities apply only to thestandard carriage/fork combination and cannot beused for other attachments.

Elevation:

Numbers at left side of chart (-4' to 48') representelevation at heel of horizontal fork as measuredfrom level ground. Maximum elevation with boomfully raised and extended is 36 feet. Elevation relatesto dimension “A” shown on serial number platelocated on right cab wall.

Boom Extension

Numbers across bottom of chart (0' to 24') andnumbers parallel to boom (2' to 18') represent boom

extension as measured from fully retracted positionto extend position. These numbers do not reflecttotal boom length, only the number of feet ofextension from fully retracted position.

Number decals on boom section number two (4,8,12, 16 and 20) relate directIy to boom extension. Thelargest number which can be read from operator’sseat indicates total boom extension.

Boom extension relates to dimension “D” shown onserial number plate.

Boom extension relates to dimension “D” shown onserial number plate.

Boom Angle

Numbers at ends of angled lines (-4 to 70)represent angle of boom to horizontal as measuredfrom horizontal plane at ground level. Maximumangles are 4 below horizontal with boom fullylowered to 70 above horizontal with boom fullyraised.

A boom angle indicator is located on left side ofboom section number one to show boom angle. Besure machine is level from front to rear or indicatorwill provide incorrect reading.

Load Center

Loads shown on rated capacity chart are based onthe load center being two feet above and two feetforward of surfaces of horizontal forks as indicatedby dimensions “B” and “C” on serial number plate.

The load center of a load is the center of gravity ofthe load. For regularly shaped loads of the samematerial, such as a pallet of blocks, the center ofgravity can be located by measuring the load to findits center. For irregular loads, or loads of dissimilarmaterials, keep the heaviest part of the load as closeto the heel of the forks as possible.

In all cases, the load center must be centeredbetween the forks.

Load Limits

Some capacities shown on the rated capacity chartare based on machine stability and some are basedon hydraulic lift capacity. The “common sense” or“feel” an experienced operator might apply inregard to “tipping loads” DOES NOT APPLY tohydraulic load limits . Exceeding load limits cancause damage or in some cases, the machine to tipover.

All loads shown on rated capacity chartare based on machine being on firm, levelground; the forks being positioned evenlyon carriage; the load being centered onforks; proper size tires being properlyinflated; and the handler being in goodoperating condition.

Rated Capacity Chart

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PARKINGTurn off all electrical accessories.

Allow engine to cool at idle speed for a fewminutes and then turn off. Remove ignitionkey.

Fill fuel tank to minimize condensation.

Disconnect battery if unit is in an area wheretampering seems possible.

Lock cab (if so equipped).

Position unit in a safe, level parking area.

Apply parking brake and chock wheels.

Retract and lower boom fully.

Clean and inspect machine thoroughly and per-form all required maintenance.

Coat all cylinder rods with a good grade ofgrease or rust preventative.

Park machine in a dry enclosure and removebatteries.

Prepare engine in accordance with enginemanufacturer’s instructions.

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BOOM EXTENSION IN FEET FROM TIRE TO LOAD CENTER (24 IN FRONT OF FORK FACE).FIGURES SHOWN ARE STACKING CAPACITY TRUCK LEVEL.RATED LIFTING CAPACITIES SHOWN ARE WITH MACHINE ON A FIRM. LEVEL SURFACEWITH UNDAMAGED. PROPERLY INFLATED. HYDROFILLED (CALCIUM CHLORIDE AND WATER)TIRES. MACHINE SPECIFICATIONS AND STABILITY ARE BASED ON RATED LIFT CAPAC-ITIES AT SPECIFIC BOOM ANGLES AND BOOM LENGTHS. IF SPECIFICATIONS ARE CRIT-ICAL. THE PROPOSED APPLICATION SHOULD BE DISCUSSED WITH YOUR DEALER.DO NOT EXCEED RATED LIFT CAPACITY LOADS. AS UNSTABLE AND DANGEROUS MACHINECONDITIONS WILL RESULT. DO NOT TIP THE MACHINE FORWARD TO DETERMINE ALLOW-ABLE LOAD.

CAPACITY LIMITS FOR THIS UNIT ARE BASED IN ACCORDANCE WITH ANSI 856.6LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT.

CAPACITY CHART: MODEL 534D-8 RATED CAPACITY 2 FT. LOAD CENTER

534D-89103-3311

USE WITH 9045-5007 48 CARRIAGE 9045-5008 66 CARRIAGE

STORAGE

Parking brake may not hold machine on agrade

FOR OTHER ATTACHMENTS CONSULTFACTORY FOR LOAD RATING.USE LARGEST NUMBER VISIBLEFROM CAB TO DETERMINE BOOMEXTENSION. MATCH WITH BOOMANGLE TO DETERMINE ALLOWABLELOAD.

Intervals shown are for normal (8 hour day) usageand conditions. Adjust intervals for abnormalusage and conditions.

Apply a light coating of engine oil to all linkagepivot points.

Clean lubrication fittings before lubricating.

Clean air filter and cleaner housing using dieselfuel. Dry components thoroughly using a lint freecloth.

Check lubricant levels when lubricant is cool.

Drain engine and gear cases only after operationwhen lubricant is hot.

Lubricantion Notes

TIRE SPECIFICATIONS

Standard 13:00 x 24-12 ply ratingfront 65 psi, rear 55 psi.Tires filled with CaCl mix, front500 lbs., rear 420 lbs.Options17:50 x 25 - 12 ply (flotation front only)

Recommended Lubricants & Capacities

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LUBRICATION & MAINTENANCE DIAGRAM

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Suggested Lubrication & Maintenance Frequencies

.CG - Chassis GreaseHF - Hydraulic FluidEO - Engine OilGO - Gear OilATF - Transmission Fluidl - Lube

INS - Inspect & FillCH - Change

*#5 Boom Bearing Pads (extend boom fully and coat all wear paths on boom sections 2 and 3 with light coat of grease-retract and extend boom fully three times and wipe excess grease from bearings). Check for wear & shim or replace as required-no wear permitted past bevel-shims are 1/16" thick

Hours

NOTES

NOTES

NOTES

Documents

IMPORTANT SAFETY NOTICE - JLG Industries Telehandlers/534B-6_534B-8...IMPORTANT SAFETY NOTICE Safe operation depends on reliable equipment and proper operating procedures. Performing